Attic hatch

ABSTRACT

A prefabricated attic hatch includes a frame comprising an outer frame and an inner frame. The inner frame encloses a central insulating panel which is fabricated from metal-skinned insulating foam. A preferred material for the panel is metal insulated door waste material. A method of fabricating attic hatches includes the use of metal insulated door waste material.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional application of U.S. patent applicationSer. No. 10/249,315 filed on Mar. 31, 2003 entitled “Attic Hatch”.

FIELD OF THE INVENTION

The present invention relates to prefabricated insulated attic hatchesfor use in residential and commercial construction.

BACKGROUND OF THE INVENTION

Openings into attics are common in most homes. In cold climates, theattic is not used for living space or for storage. Typically, an atticis filled with an insulating material, either fibreglass batting or foamchips, between the ceiling joists. The attic opening is usually coveredwith a hatch made from a piece of plywood or OSB framed with 2×4 or 2×6lumber, which is fabricated on site using surplus materials. The hatchitself is often not insulated, or a small piece of fibreglass batting orrigid foam is glued to the topside of the hatch.

Therefore, there is a need in the art for a prefabricated, insulatedattic hatch.

SUMMARY OF THE INVENTION

The present invention is directed to a pre-fabricated insulated attichatch. In general terms, the hatch is configured to fit between thebottom pieces of adjacent roof trusses and framing members between thetrusses. The hatch comprises a frame and a central insulating panel. Ina preferred embodiment, the central insulating panel is a flat piece ofinsulating

Summary of the Invention

The present invention is directed to a pre-fabricated insulated attichatch. In general terms, the hatch is configured to fit between thebottom pieces of adjacent roof trusses and framing members between thetrusses. The hatch comprises a frame and a central insulating panel. Ina preferred embodiment, the central insulating panel is a flat piece ofinsulating material which is clad on at least one of its upper and lowersurfaces with a rigid material such as metal or fiberglass. Theinsulating material may be any plastic foam such as polyurethane foam orpolystyrene foam. A preferred material for the central insulating panelis identical to that used to manufacture metal or fiberglass insulateddoors.

Therefore, in one aspect, the invention comprises an attic hatchcomprising an outer frame encircling a central panel comprising a metalclad insulating foam, wherein the central panel is metal clad on bothsides and is framed by an inner frame.

In another aspect of the invention, the invention comprises a method ofconstructing an attic hatch comprising a central insulating panel, themethod comprising the steps of receiving insulated metal door wastematerial and forming the central insulating panel from the wastematerial.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will now be described by way of an exemplary embodimentwith reference to the accompanying simplified, diagrammatic,not-to-scale drawings. In the drawings:

FIG. 1 is a cross-sectional view of one embodiment of the invention.

FIG. 2 is a detail cross-sectional view of one comer of the attic hatchshown in FIG. 1.

FIG. 3 is a schematic perspective view of one embodiment.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

The present invention provides for a pre-fabricated insulated attichatch. All terms not defined herein have their common art-recognizedmeanings.

As seen in the Figures, the invention comprises a rectangular hatchadapted to fit an attic opening in a residential or commercial building.It may fit between truss members (T) and cross pieces (C), which may besimple 2×4 lumber. A frame (10) includes an outer frame (12) and aninner frame (14). The inner frame (14) is preferably a PVC extrusiondefining a channel which fits around the periphery of a rectangularcentral insulating panel (16). As is shown in a partially exploded view,a plurality of panels (16) may be stacked to provide additionalinsulating value. The inner frame may have a mating tongue (18) andgroove (20) configuration to lock the stacked panels (16) into place.

Each panel (16) is preferably a fibreglass or metal skinned panel havinga foam core, such as polyurethane or polystyrene foam, which are wellknown in the art. In a preferred embodiment, the panels are metalinsulating door material, and more preferably recovered from wastematerial discarded during door manufacture. There is usually no use forsuch waste material and it is typically discarded to landfills. Thedimensions of such waste material are usually such that panels ofadequate size for attic hatches may be cut from them. As used herein,“waste material” refers to material remaining after the door cutout ismade, regardless of whether the material is actually discarded or not.

The outer frame is preferably an aluminum extrusion which has a lowerretaining flange (22) which serves to vertically support the panels(16). A perimeter flange (24) fits between a truss member (T) and theinterior ceiling drywall (D), retaining the outer frame in position. Alip between the retaining flange (22) and the perimeter flange (24)keeps the retaining flange (22) flush with the drywall surface.Therefore, the bottom surface of the panel (16) and the retaining flange(22) may be painted or textured to match the rest of the ceiling.

A third section of the outer frame defines a channel (26) which supportsa vertical divider (28), which may be plywood, oriented strandboard or arigid plastic material. The purpose of the divider is to dam up anyinsulating material such as foam chips which is used to insulate theattic and prevent the escape of such material down the attic opening.

A flexible seal (30) between the outer frame (12) and the inner frame(14) prevents drafts. The inner frame (14) may have a peripheral seal(32) such as a mohair seal to provide additional sealing between theinner and outer frames (12, 14) and between the divider (28) and theinner frame (14) of stacked panels (16).

As will be apparent to those skilled in the art, various modifications,adaptations and variations of the foregoing specific disclosure can bemade without departing from the scope of the invention claimed herein.

1. A method of constructing an attic hatch comprising a centralinsulating panel, the method comprising the steps of receiving insulatedmetal door waste material and forming the central insulating panel fromthe waste material.
 2. The method of claim 1 wherein the attic hatchcomprises an outer frame encircling a central panel comprising a metalclad insulating foam, wherein the central panel is metal clad on bothsides and is framed by an inner frame.
 3. The method of claim 2 whereinthe outer and inner frames are rectangular and the inner frame fitsclosely within the outer frame.
 4. The method of claim 3 wherein theouter frame comprises means for attaching a vertical separator.
 5. Themethod of claim 4 wherein the means for attaching a vertical separatorcomprises an upward facing groove for receiving a vertical separator. 6.The method of claim 2 wherein the inner frame comprises a tongue andgroove configuration on opposing horizontal sides of the inner frame,such that identical inner frames may be stacked vertically with thetongue of one frame mating with the groove of an adjacent frame.
 7. Themethod of claim 2 further comprising a resilient seal disposed betweenthe inner and outer frames.